KR20210152052A - Manufacturing method of three-dimensional sculpture and three-dimensional object by the method - Google Patents

Abstract

An object of the present invention is to provide a configuration related to a three-dimensional sculpture and a manufacturing method thereof targeting a lattice region and an outer frame region disposed around the entire lattice region due to a uniform shape and a strong bond, A method for manufacturing a three-dimensional object based on repetition of the achievable process of forming the powder layer 3 and sintering with a laser beam or electron beam, wherein, in the lattice region 1, the beam having a predetermined spot diameter After forming the sintered layer 41 by scanning a plurality of times in one direction at a predetermined interval, the sintered layer 42 is formed by performing the same scanning in the other direction intersecting the one direction again, In the outer frame region 2, the continuous sintered layer 43 is formed by scanning the beam having a predetermined spot diameter over the entire region of the lattice region 1 surrounded by the inner line and the outer line. A method for manufacturing a three-dimensional object that can achieve the above object by doing so, and a three-dimensional object based on the method.

Description

Manufacturing method of three-dimensional sculpture and three-dimensional object by the method

In a state based on lamination based on sequential repetition of the steps of forming a powder layer by spraying powder accompanied by a slide of a squeegee and sintering the powder layer with a laser beam or electron beam, the surrounding outer frame and The present invention relates to a method for manufacturing a three-dimensional object targeting a lattice (lattice) structure inside thereof, and a three-dimensional object based on the method.

A method for manufacturing a three-dimensional object based on lamination based on sequential repetition of the steps of forming a powder layer by spraying powder accompanied by a slide of a squeegee and sintering the powder layer with a laser beam or electron beam is well known to be.

Among the three-dimensional objects produced by the three-dimensional object manufacturing method, there are cases where air permeability, that is, a gas release structure, is required inside the object, such as a cavity-type mold product and a filter product, and in these products, the density is It results in the production of a low-weight, three-dimensional sculpture.

As a method for manufacturing a three-dimensional object requiring such air permeability, for example, in Patent Document 1, a gas flow path having a porous structure, that is, a porous structure is formed. As long as it is produced by lowering the density of the material, the strength as a sculpture is small, but the flow path through which the gas flows is indeterminate and not linear, so that the flow rate of the gas is small.

On the other hand, in Patent Document 2, after sintering a specific metal powder layer by linearly scanning a laser beam having a predetermined spot diameter a plurality of times at predetermined intervals (sintering by the first raster configuration) ), the metal powder layer adjacent to the upper side is sintered by the same laser beam in the direction orthogonal to the linear direction (sintering by the second raster configuration), and lamination of each metal powder and the above A method for manufacturing a lattice region by repeating scanning with a laser beam in the same direction orthogonal to each other is provided (Claim 3 and Fig. 4).

That is, in the invention of Patent Document 2, the sintering along the transverse direction (X direction) and the longitudinal direction (Y direction) for shaping the periphery of the ventilation hole in the lattice region is alternately (alternately) sintering for every two layers.

As long as reference is made to FIG. 2 of Patent Document 2, as shown in FIG. 10A, either the longitudinal direction or the transverse direction scanned by the laser beam coincides with the sliding direction of the squeegee, and such coincidence is three-dimensional It is based on the technical common sense of efficiently using the space in the manufacture of sculptures.

By the way, the squeegee slides with a predetermined pressing force to flatten the surface of the metal powder layer. When the squeegee slides on the upper side of the line-shaped sintered layer by scanning the laser beam in a direction orthogonal to the direction, the thickness of the metal powder layer to be pressed is Between the parts where the metal powder layer is also superposed on the metal powder layer, even if the width in the sliding direction of the squeegee is larger than the width of the sintered layer, the degree of compression received by the pressure from the tip in the direction in which the squeegee slides is different. inevitably occurs.

As a result of such a difference, when the laser beam is scanned in a direction orthogonal to the linear sintering performed after the slide of the squeegee, as shown in Fig. 10B, unevenness accompanied by fine irregularities in the vertical direction It is inevitable that the sintered layer will be molded (by the way, for better understanding, the concavo-convex shape of FIG. 10B is exaggerated).

In addition, in the case of alternate sintering for every two layers as in the invention of Patent Document 2, bonding along a two-dimensional plane in which the lateral direction (x direction) and the longitudinal direction (y direction) are in contact with each other in the vertical direction is realized. In the same height direction, the bonding through the three-dimensional cube formed along the transverse (x-direction) and longitudinal (y-direction) directions in the same height direction is non-uniform, so that the strength of the lattice region is never sufficient.

Furthermore, in the invention of Patent Document 2, although the outer frame region is indicated on the drawing, the relationship between the sintering of the lattice region and the sintering of the outer frame region is not explained at all.

Japanese Patent No. 5776004 Publication Japanese Patent No. 6532180 Publication

An object of the present invention is to provide a method for manufacturing a three-dimensional object targeting a lattice region with a uniform shape and a strong bond and an outer frame region disposed outside the region, and a configuration of a three-dimensional object by the method is doing with

In order to solve the above problems, the basic configuration of the present invention is,

(1) Manufacture of a three-dimensional sculpture based on lamination based on sequentially repeating the steps of forming a powder layer by spraying powder accompanied by a slide of a squeegee and sintering the powder layer with a laser beam or electron beam As a method, sintering in each powder layer is performed for a lattice region having air permeability and an outer frame region connected to the outside of the region and arranged around the entirety of the region, and the lattice region is targeted. For each powder layer being used, a laser beam or an electron beam having a predetermined spot diameter is scanned in one direction at a predetermined interval and in parallel multiple times in a state of bonding the opposing outer frame regions to one another, thereby selecting one direction in one direction. After forming the sintered layer according to the following, a laser beam or an electron beam having a predetermined spot diameter in a state of bonding the outer frame regions facing each other in the other direction intersecting the one direction in the same respective powder layer is predetermined. A sintered layer in the other direction is formed by scanning in parallel multiple times at an interval of One sintering and the other sintering are combined in an overlapping state, and in the non-intersecting region, only one or the other sintering is performed, and for the outer frame region, it is surrounded by the inner line and the outer line. A method for manufacturing a three-dimensional object in which a continuous sintered layer is formed by scanning a laser beam or an electron beam having a predetermined spot diameter around the entire perimeter;

(2) As the shape of the outer frame region, the inner line and the outer line have the same central position, respectively, and either a regular polygonal shape or a curved shape having a mutually similar relationship is adopted (1) A method of manufacturing a three-dimensional sculpture of

(3) the outer frame region is separated by a predetermined width and is separated by a parallel line selected in a specific direction, and in a stage before or after the sintered layer forming in the lattice region, or an intermediate stage thereof, the parallel The manufacturing method of the three-dimensional sculpture of the above (1), characterized in that the laser beam or electron beam is scanned in a direction orthogonal to the direction

is made of

In the three-dimensional object according to the basic configuration (1), the basic configuration (2), and the basic configuration (3), one direction and the other direction by scanning of a laser beam or an electron beam (hereinafter abbreviated as “beam”) Even when any of the squeegees is perpendicular to the sliding direction of the squeegee, the squeegee slides on the upper side of the line-shaped sintered layer formed in the direction intersecting the direction, so as in the invention of Patent Document 2, the beam scanning direction and the squeegee In the case where the sliding directions of are orthogonal to each other, due to the difference in the thickness of the metal powder layer as a cause, the sintered layer is formed with fine irregularities in the vertical direction by the non-uniform pressing by the slide of the squeegee as shown in Fig. 10B. can be avoided

In addition, in the case of the basic configuration (1), in each powder layer, a line-shaped sintered layer by scanning a beam in one direction and a line-shaped sintering layer by scanning a beam in the other direction are formed by the same powder layers. By three-dimensional bonding in the same height range to be formed, the sintered layer along one direction and the sintered layer along the other direction intersect, and in the crossed region, one sintering and the other sintering overlap. In a region that is bonded in a bonded state and does not intersect, only one side or the other side is sintered, and a three-dimensional cube is clearly stronger than the bonding along two-dimensional planes in contact with each other in the vertical direction as in Patent Document 2 invention. bonding is performed, and furthermore, it is possible to secure a lattice region by a strong bonding.

Furthermore, in the basic configuration (1), in each powder layer, sintering of the lattice region and sintering of the outer frame region can be sequentially and efficiently realized.

1A to 1C show a manufacturing method of the basic configuration 1 when the shape of the sintered layer by scanning the beam along one direction and the other direction is linear, and FIG. 1A shows that both directions are It is a plan view of an orthogonal embodiment, FIG. 1B is a top view of an embodiment in which both directions cross each other obliquely, FIG. 1C is a first layer in the scanning direction of the beam connecting A-A in FIGS. 1A and 1B. It is a cross-sectional view when the second layer is sequentially formed from
2A to 2C show a manufacturing method of the basic configuration 1 when the shape of the sintered layer by scanning the beam along one direction and the other direction is a wavy shape, and FIG. 2A shows that the curve is regular. It is a plan view of an embodiment in which both directions of a waveform shape changing with It is a top view, and FIG. 2C is sectional drawing in the case of forming the 2nd layer sequentially from the 1st layer in the scanning direction of the beam linking A-A of FIGS. 2A and 2B.
3A and 3B show an embodiment of the basic configuration 2, FIG. 3A is a plan view illustrating a case of a square which is a typical example of a regular polygonal shape, and FIG. 3B is a circular shape that is a typical example of a curved shape. It is a plan view showing the case.
Fig. 4A is a plan view showing an embodiment of the basic configuration (3), in which the square of Fig. 3A is adopted, and the parallel lines are in the direction of a specific side in the square (both arrows indicate Indicates a direction that is parallel to and orthogonal to).
Fig. 4B shows an embodiment of the basic configuration (3), and in a state where the square of Fig. 3A is adopted, parallel lines form a regular polygonal shape or a curved shape with respect to a predetermined width on the inner line and the outer line It is a top view which shows the case where it is a direction which forms a maximum distance in the area|region surrounded by (double-sided arrows indicate a direction orthogonal to a parallel direction).
Fig. 4C shows an embodiment different from the basic configuration (3) in the sintering of the outer frame region, and in the state in which the circle of Fig. 3B is adopted, the beam is moved along the trajectory in a similar relationship to the inner line and the outer line. It is a top view which shows the case of scanning (a curved one-sided arrow shows the scanning direction of a beam).
5A and 5B are plan views showing the relationship between the scanning direction of the beam and the sliding direction of the squeegee, and FIG. 5A shows an embodiment in which either one direction or the other direction is orthogonal to each other. , an embodiment in which both directions are diagonally intersected is shown.
In addition, the white arrow indicates the direction in which the squeegee slides while spraying the powder.
6A to 6C show an embodiment of replenishing the insufficient metal powder when the powder runs short between the sintered regions in the scanning step of the beam in one direction. The powder sprayed by the slide by the squeegee in the direction intersecting the scanning direction shows a state in which the amount required for powder layer molding is insufficient, and FIG. Fig. 6C shows a state in which the beam is scanned in the other direction.
Incidentally, in Fig. 6A, Fig. 6B, and Fig. 6C, illustration of the outer frame region is omitted.
7A and 7B show an embodiment in which the size of the ventilation hole is sequentially decreased according to the lamination by changing the beam spot diameter and the beam power or scanning speed, and FIG. It is a top view which shows a thing, and FIG. 7B is an up-down direction sectional drawing.
8A and 8B show that, in a state where a beam having a predetermined spot diameter is selected, the size of the vent hole is sequentially step-by-step by setting the intervals between beams scanned in parallel in one direction and the other direction to be small sequentially step by step. 8A is a plan view showing that the beam spacing becomes smaller step by step, and FIG. 8B is a vertical cross-sectional view showing the same state as in the case of FIG. 8A ( The dotted line shows a state in which a beam at a stage before the change and a beam at a stage after the change overlap each other with respect to a beam being scanned in the other direction in a region where the distance between the beams is gradually decreased. ).
Fig. 9 is a vertical cross-sectional view showing the configuration of an embodiment in which a partial region surrounded by the lattice region is tapered.
10A and 10B show the configuration of the invention in Patent Document 2, and FIG. 10A is a plan view in a step in which the squeegee slides, and FIG. 10B is a vertical cross-sectional view in the step. In addition, the white arrow indicates the direction in which the squeegee slides while spraying the powder.

When the three-dimensional molded object having the outer frame and the inner lattice structure obtained by the basic configurations (1), (2) and (3) is used as a mold, metal powder is naturally used as the powder.

On the other hand, when the three-dimensional object is a product other than a mold such as a filter, the powder does not necessarily have to be a metal powder, and a plastic powder can also be used as a typical example. There is no change in any case.

In a state where such materials are appropriately selected, the basic configuration 1 is a powder with a slide of a squeegee 6, as shown in Figs. 1A, 1B, 1C and Figs. A method for manufacturing a three-dimensional object based on lamination based on sequentially repeating the steps of forming a powder layer 3 by spraying and sintering the powder layer 3 with a laser beam or electron beam, wherein each powder The sintering in the layer 3 is carried out by the lattice region 1 having air permeability and the outer frame region 2 connected to the outside of the region 1 and disposed around the entire periphery of the region 1 . For each powder layer 3 that is a target and targets the lattice region 1, a laser beam or an electron beam having a predetermined spot diameter is directed in one direction at a predetermined interval, and the outer frame region faces each other. (2) After forming the sintered layer 41 along one direction by scanning in parallel multiple times in the state of bonding (2), in the same powder layer 3 again, in the other direction intersecting the one direction , forming a sintered layer 42 in the other direction by parallelly scanning a laser beam or an electron beam having a predetermined spot diameter a plurality of times at a predetermined interval in a state where the outer frame regions 2 facing each other are bonded. and the sintered layer 41 along one direction and the sintered layer 42 along the other direction intersect, and in the intersecting region, one sintered layer and the other sintered layer are combined in an overlapping state. In the non-intersecting area, only one or the other side is sintered, and for the outer frame area 2, a predetermined spot diameter is provided around the entire perimeter in a state surrounded by the inner line and the outer line. It is a method of manufacturing a three-dimensional object in which a continuous sintered layer 43 is formed by scanning a laser beam or an electron beam.

In the basic configuration (1), the lattice region 1 and the outer frame region 2 are laminated and sintered for each layer, but the outer frame region 2 is surrounded by the inner line and the outer line, and both It has a width formed by the line of

Various embodiments can be adopted for the shape of the outer frame region 2 formed by such an inner line and an outer line, but a typical example thereof is that the inner line and the outer line have the same center position, respectively, and It is a basic configuration (2) characterized by employing either a regular polygonal shape or a curved shape in a mutually similar relationship, and the square shape shown in FIG. 3A and the circular shape shown in FIG. 3B are the simplest shapes. An embodiment is shown.

However, as a polygonal shape, a hexagonal shape and a rectangular shape can also be employ|adopted according to a square shape, and as a curved shape, an oval shape can also be employ|adopted according to a circular shape.

In the basic configuration (2), the outer frame region 2 having a uniform structure can be formed by the inner line and the outer line having a similar shape.

As for the sintering of the outer frame region 2, as in the basic configuration (1), a continuous sintered layer 43 may be formed in the region surrounded by the inner and outer lines, and such a continuous sintered layer 43 ) is usually performed regardless of the formation of the sintered layers 41 and 42 of the lattice region 1 in many cases.

However, normally, the outer frame region 2 is separated by a predetermined width and separated by parallel lines selected in a specific direction, prior to forming the sintered layers 41 and 42 in the lattice region 1, Alternatively, the basic configuration (3) characterized in that a laser beam or an electron beam is scanned in a direction orthogonal to the parallel direction is often adopted in a later step or an intermediate step thereof.

In the case of the basic configuration (3), on the other hand, processing on a computer, such as dividing by parallel lines separated by a predetermined width, is easy, and simple control can be realized by specifying the scanning direction of the beam.

In the basic configuration (3), a step before or after the sintering of the lattice area (1) is often selected for the sintering of the outer frame region (2), but an intermediate step thereof is also selectable.

However, as the intermediate step, in almost all cases, after sintering in one direction is completed, the previous step of performing sintering in the other direction is selected.

The basis is that it is necessary to continuously realize both the shaping of the sintered layer 41 in one direction and the sintered layer 42 in the other direction.

In the basic configuration (3), in the state where the regular polygonal shape of the basic configuration (2) is selected, when a parallel line selects the direction of a specific side of the regular polygonal shape, as shown in Fig. 4A, the specific side For , it is possible to realize simple scanning that sintering is completed by scanning the beam in the direction orthogonal to the parallel direction, and sintering is completed for the other side by beam scanning in the divided area. have.

In the basic configuration (3), in the state where the regular polygonal shape or the curved shape of the basic configuration (2) is selected, as shown in FIG. 4B , parallel lines are regular polygons of the basic configuration (2) with respect to a predetermined width. If the direction forming the maximum distance in the area surrounded by the inner and outer lines forming a shape or curved shape is selected, the sequential scanning position is slid from the end of one parallel line to the end of the other parallel line. In this case, relatively simple control of the scanning width of the beam can be realized by sequentially increasing the scanning width from the initial zero stage, setting it to the maximum state in the intermediate stage, then sequentially decreasing it and setting it to zero.

Further, when the regular polygonal shape is a square, as long as the direction of the parallel line is the direction showing the maximum width is formed by the mutually adjacent vertices of the inner line and the outer line, it is inevitably 45° with respect to the parallel side. It comes down to indicating the direction.

Separately from the sintering according to the basic configuration (3), as shown in Fig. 4C, at a stage before or after the molding of the sintered layers 41 and 42 in the lattice region 1, or an intermediate stage thereof, as shown in Fig. 4C, the basic A sintering method by scanning a beam along a locus similar to the inner line and the outer line forming the regular polygonal shape or the curved shape of the configuration (2) can also be employed.

In the case of a sintering method that moves along a locus line in such a similar relationship, a simple control of sequentially changing the size of the pattern as it moves away from the central position in a state in which a pattern of a trajectory according to the similar shape is set in advance. can be realized

In addition, in the sintering method by the trajectory, a step before or after the sintering of the lattice region 1 is often selected in many cases, but even if an intermediate step is selected, sintering in one direction is It does not change from the case of the basic structure (3) that the previous stage in which completion|finish and sintering in the other direction is started is selected.

As sintering of the beam in the outer frame region 2, both methods of setting the same spot diameter as in the case of adopting a spot diameter larger than the spot diameter in the lattice region 1, and setting the number of scans higher can be selected, but a larger beam diameter of electrons is suitable for efficient sintering.

In particular, for the laser beam or electron beam scanning the outer frame region 2, a spot diameter larger than the spot diameter in the lattice region 1 is selected, and the beam power per unit area in the spot diameter When the embodiment characterized in that the power density equal to the power of the beam in the lattice region 1 is adopted, the outer frame region 2 is also the same as that of the lattice region 1 A sintered state by strong bonding can be realized.

의 범위에서 선택되는 한편, 상기 소정의 간격으로서는, 0.06 ㎜∼1.0 ㎜를 선택하고, 통기 구멍(11)의 폭에 대해서는 0.01 ㎜∼0.4 ㎜의 범위로 설정하는 경우가 많다.The spot diameter of the beam in the basic configuration (1) is usually 0.05 mmφ to 0.6 mm

On the other hand, in many cases, 0.06 mm to 1.0 mm is selected as the predetermined interval, and the width of the ventilation hole 11 is set in the range of 0.01 mm to 0.4 mm in many cases.

In the case of the basic configuration (1), the line shape by parallel scanning in the lattice region 1 along one direction and the other direction in each powder layer 3 is selected from various shapes. It is possible, and FIGS. 1A and 1B show a case of a straight line shape, and FIG. 2A shows an embodiment in which the curve is a continuous wave shape while regularly changing ( FIG. 2A , the curvature direction changes sequentially and alternately while A case in which a continuous arc shape is shown.) is shown, and FIG. 2B shows an embodiment of a continuous wave shape while a broken line changes regularly ( FIG. 2B shows that the broken line direction changes sequentially and alternately at about 45° Although the case where it is continuous is shown.), a shape by combining a wavy shape and a linear shape by these is naturally employable.

In the case of a linear shape, simple scanning can be realized, and in the case of a corrugated shape, the sintering density per unit area of a plane along the scanning direction of the beam can be set larger than in the case of a linear type.

When a straight line connecting both ends of each line of the sintered layer 41 in one direction in the lattice region 1 and a straight line connecting both ends of each line of the sintered layer 42 in the other direction are referenced, both A typical example is that the angle of the direction is a right angle as shown in Figs. 1A and 2A, but it is also possible to select an oblique direction as shown in Figs. 1B and 2B.

However, when it is considered that the most efficient sintering is realized when it is orthogonal, it is often set to 45° or more even in an oblique direction. An angle of 45° to 90° is often chosen.

In addition, although either one direction and the other direction are selected for the beam scanning in the outer frame area|region 2, as shown to FIG. 1A, FIG. For the outer side of the region 2, molding by a state parallel to the outer side of the lattice region 1 is employed.

When the efficient use of space is considered, as shown in Fig. 5A, the sintered layer 41 in one direction or the sintered layer 42 in the other direction in the sliding direction of the squeegee 6 and scanning the beam. When both sintering directions are compared, a state not only coincident with the sliding direction but also orthogonal is realized.

In such a state, for example, as shown in FIG. 5A , even if the sintered layer 42 in the orthogonal direction exists, the squeegee 6 slides on the upper side of the sintered layer 41 in the coincident direction. As described above, it is possible to avoid making the surface of the powder layer 3 non-uniform as shown in Figs. 10A and 10B described above with respect to the invention of Patent Document 2.

However, in the embodiment shown in FIG. 5A , in the region where the line-shaped sintered layer 42 orthogonal to the slide direction on the lower side exists and the region sandwiched by the line-shaped sintered layer 42, the squeegee 6 The thickness of the powder layer 3 formed also differs with the slide, and as a result, some difference cannot but occur in the influence of the pressing pressure from the side end of the squeegee 6 in the slide direction.

Specifically, since the influence of the pressing pressure at the tip in the moving direction of the squeegee 6 is greater in the region where the line-shaped sintered layer 42 is not present than in the region where the line-shaped sintered layer 42 is present, the accuracy is higher than in Fig. 10B. Even if it is remarkably low, it will be in a slightly recessed state, and as a result, a fine uneven|corrugated shape may arise alternately along the sliding direction of the squeegee 6 .

On the other hand, as shown in FIG. 5B, the straight line connecting both ends where scanning is performed in the lattice region 1 along the sintered layer 41 in one direction and the sintered layer 42 in the other direction as a reference In one case, in the case of the embodiment characterized in that the one direction and the other direction and the sliding direction of the squeegee 6 cross each other at an angle, the sliding direction of the squeegee 6 as shown in FIG. 5A and Since the line-shaped sintered layer 42 along the orthogonal direction does not exist in the lattice region 1, it is possible to avoid the occurrence of irregularities in the powder layer 3 along the sliding direction of the squeegee 6, and Based on the molding of the powder layer 3, the lattice region 1 can be formed in a more stable state.

In addition, the area where the sintering layer 41 of the beam in one direction and the sintering layer 42 of the beam in the other direction overlap is very narrow, and the area where only one or the other side of the sintering is performed. As long as the influence on the slide of the squeegee 6 is not different, the existence of the sintered layers 41 and 42 due to the overlap is not a factor that negates the advantage of the embodiment shown in Fig. 5B.

In the basic configuration (1), when sintering of the beam in one direction is performed, a part thereof shifts to the sintered layer 41 side, and as a result, each region surrounded by the sintered layers 41 on both sides is shown in FIG. 6A As shown, the powder sprayed by the slide by the squeegee 6 in the direction intersecting the scanning direction may be insufficient as the amount required for forming the powder layer 3, and in particular, the linear The greater the width of the region sandwiched by the sintered layer 41, the greater the tendency for the insufficient state to occur.

In spite of such a shortage condition, when sintering is immediately performed by scanning the beam in the other direction, the line-shaped sintered layer 42 formed by the scanning in the other direction is non-uniform, and furthermore, non-uniform The lattice region 1 cannot but be molded.

In order to avoid such a situation, in the basic configuration (1), as shown in Fig. 6B, by sintering by scanning in the lattice region 1 along one direction, adjacent sintered layers ( 41), when the powder of the powder layer 3 is insufficient, in a step before sintering by scanning in the other scanning direction is performed, the sliding of the squeegee 6 along the above direction is performed again. An embodiment characterized in that the insufficient powder is replenished by interposing the powder dispersion can be employed.

In the above embodiment, as shown in Fig. 6C, it becomes possible to realize a uniform sintered layer 42 during sintering of the next other beam.

The ventilation hole 11 to be formed in the basic configuration (1) is formed in both the sintered layer 41 in one direction and the sintered layer 42 in the other direction, so that the sintered layers 41 and 42 are formed in all directions. ) is surrounded by

However, the width of the line forming these sintered layers 41 and 42 is not necessarily the same width at all.

That is, as shown in Figs. 7A and 7B, as the stacking is repeated, the beam spot diameter in the lattice region 1 is sequentially increased, and the beam power is sequentially increased or the beam scanning speed is increased. An embodiment characterized in that the size of the ventilation hole 11 is set to be small sequentially can be adopted by successively reducing the ?

Furthermore, as shown in Figs. 8A and 8B, the lattice region 1 is scanned as lamination is repeated, and the interval between laser beams or electron beams having a predetermined spot diameter is set to be small sequentially in stages. By doing so, an embodiment characterized in that the size of the ventilation hole 11 is set to be small in succession step by step can also be adopted.

When the cavity mold is manufactured in each of the above embodiments, the area of the outlet at which the air flow is blown is smaller than the inlet at which the air flow is blown, so that the required pressure is reduced. ejection can be realized.

Hereinafter, it demonstrates based on an Example.

[Example]

In the shaping of the lattice region 1, there is a case where a gas evacuation pipe is arranged on the lower side, and as a result of the arrangement, as shown in FIG. 9 , the region in which the outer frame region 2 is to be formed. In some cases, the base plate 5 is provided only on the lower side of the lattice region 1, and the lattice region 1 is molded without the base plate 5 being provided below the region where the lattice region 1 is to be molded. .

In such a case, it is indispensable to form the inner lattice region 1 sequentially from the peripheral outer frame region 2 .

In Example 1, as shown in FIG. 9, the lattice area|region 1 shape|molded by the sintering accompanying the scanning of the beam in the lattice area|region 1 along one direction and the other direction is inside It is characterized in that the lattice region 1 having an inwardly tapered shape is formed by enclosing the void of

By adopting such a tapered shape, it is possible to realize the lattice region 1 having a necessary vertical width and accompanied by a predetermined strength.

[Industrial Applicability]

The present invention is innovative in that it can realize a lattice structure with a strong bond and a uniform shape, and the range of use of three-dimensional modeling accompanying the lattice structure is wide.

1: Lattice area
11: vent hole
12: taper area
2: Outer frame area
3: powder layer
41: sintered layer in one direction
42: sintered layer in the other direction
43: continuous sintered layer
5: base plate
6: Squeegee

Claims (15)

A method for manufacturing a three-dimensional object based on lamination based on sequentially repeating the steps of forming a powder layer by spraying powder accompanied by a slide of a squeegee and sintering the powder layer with a laser beam or electron beam, The sintering in each powder layer targets the air permeable lattice region and the outer frame region that is connected to the outside of the region and is disposed around the entire perimeter of the region, and targets the lattice region. For the powder layer, a sintered layer along one direction by scanning a laser beam or an electron beam having a predetermined spot diameter in one direction at predetermined intervals in parallel multiple times in a state of bonding the opposing outer frame regions to each other After molding, a laser beam or an electron beam having a predetermined spot diameter is applied at a predetermined interval in the same respective powder layer in the other direction intersecting the one direction, in the state of bonding the outer frame regions facing each other. A sintered layer in the other direction is formed by scanning in parallel multiple times, and the sintered layer along the one direction and the sintered layer along the other direction intersect, and in the crossed region, The other sintering is bonded in an overlapping state, and in the non-intersecting region, only one or the other sintering is performed, and for the outer frame region, the entire perimeter in a state surrounded by the inner line and the outer line. A method for manufacturing a three-dimensional object in which a continuous sintered layer is formed by scanning a laser beam or an electron beam having a predetermined spot diameter. According to claim 1,
A method for manufacturing a three-dimensional sculpture, characterized in that, as the shape of the outer frame region, either a regular polygonal shape or a curved shape in which the inner line and the outer line have the same center position and have a mutually similar relationship. According to claim 1,
The outer frame region is separated by a predetermined width and is separated by a parallel line selected in a specific direction, and is orthogonal to the parallel direction at a stage before, after or after forming the sintered layer in the lattice region, or an intermediate stage thereof. A method of manufacturing a three-dimensional sculpture, characterized in that by scanning a laser beam or an electron beam in a direction to 4. The method of claim 3,
A method for manufacturing a three-dimensional object, characterized in that the parallel line is the direction of a specific side in the regular polygonal shape according to claim 2 . 4. The method of claim 3,
A method for manufacturing a three-dimensional sculpture, characterized in that the parallel lines are the direction forming the maximum distance in the area surrounded by the inner and outer lines forming the regular polygonal or curved shape of claim 2 with respect to a predetermined width. According to claim 1,
A laser beam or electrons along a locus similar to the inner line and the outer line forming the regular polygonal or curved shape of claim 2 in the preceding stage, the subsequent stage, or the intermediate stage of forming the sintered layer in the lattice region A method of manufacturing a three-dimensional sculpture, characterized in that the beam is scanned. 7. The method according to any one of claims 1 to 6,
For the laser beam or electron beam scanning the outer frame region, a spot diameter larger than the spot diameter in the lattice region is selected, and the power of the laser beam or electron beam per unit area in the spot diameter is applied to the lattice region. A method for manufacturing a three-dimensional object, characterized in that a power density equal to the power of a laser beam or an electron beam is set. 8. The method according to any one of claims 1 to 7,
The scanning shape in the lattice region along one direction and the other direction is a straight line, a curved shape, or a continuous wave shape in which a broken line is changed regularly, and a shape resulting from the combination of the straight shape and the wave shape. A method for manufacturing a three-dimensional sculpture, characterized in that any. 9. The method according to any one of claims 1 to 8,
Manufacture of a three-dimensional sculpture, characterized in that in the lattice region along one direction and the other direction, when the straight line connecting both ends of each line to be scanned is taken as a reference, the mutual intersection angle is 45° to 90° Way. 10. The method according to any one of claims 1 to 9,
In the lattice region along one direction and the other direction, when a straight line connecting both ends of each line to be scanned is taken as a reference, the direction in which the squeegee slides is the same as that of the one direction or the other direction A method for manufacturing a three-dimensional sculpture. 10. The method according to any one of claims 1 to 9,
In the lattice region along one direction and the other, when a straight line connecting both ends of each line to be scanned is taken as a reference, the one direction and the other direction and the sliding direction of the squeegee intersect obliquely A method for manufacturing a three-dimensional sculpture. 12. The method according to any one of claims 1 to 11,
In the lattice region along one direction, the powder is in a state of being sandwiched in adjacent sintered layers formed by sintering by scanning, and sprayed by sliding with a squeegee in a direction crossing the scanning direction. When it is insufficient as the amount required for the formation of the layer, in a step before sintering by scanning in the other scanning direction is performed, the powder spraying accompanying the slide of the squeegee along the said direction is interposed again, so that the insufficient powder A method of manufacturing a three-dimensional sculpture, characterized in that supplementing. 13. The method according to any one of claims 1 to 12,
As the stacking is repeated, the spot diameter of the laser beam or electron beam that scans the lattice region is sequentially increased, and the power of the laser beam or electron beam is sequentially increased, or the scanning speed of the laser beam or electron beam is sequentially decreased. A method for manufacturing a three-dimensional object, characterized in that the sizes of the ventilation holes are sequentially set smaller by employing , or both. 13. The method according to any one of claims 1 to 12,
By scanning the lattice region as the stacking is repeated, and by setting the intervals between laser beams or electron beams having a predetermined spot diameter to be smaller in succession step by step, the size of the ventilation holes is set to be smaller step by step, characterized in that A method for manufacturing a three-dimensional sculpture. 15. The method according to any one of claims 1 to 14,
The lattice region formed by sintering accompanying laser beam or electron beam scanning in the lattice region along one direction and the other direction is set to surround the inner void, and the size of the void is increased according to the lamination. A method for manufacturing a three-dimensional object, characterized in that the lattice region is formed in an inwardly tapered shape by setting the values sequentially smaller.

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